Modern Vespa

Create airflow through a sweaty helmet. Probably not a replacement for a helmet cleaning product, but an enhancement.

First: Cheap!

Second: it was absolutely impossible to find a small clip on fan. None of the hardware, drug, and Walget or Tar-mart had appropriate fans left. Want a good deal on a 24" box fan - go now, 6" fans don't exist.

Third: Fast, easy, and no really exotic tools required. Each version - UNDER 20 minutes. The 'Classic' requires a hole saw, saber saw, or other way to make a 4" hole. The Modern version can be done with a steak knife.

Fourth: Corner store stuff. Everyone has a Radio Shack and hardware store close. Yes you can find PC fans cheaper - go for it, but for those that don't want to wade through teh internets looking for a deal this is easiest.

Fifth: Cheap!

Things to do differently: use a lamp cord with a built in switch or buy a timer; a timer like the ones that they'll be giving away towards the end of December. A self contained fan would be even faster.


If you have a better version, lets SEE it.

Radio Shack parts:
Fan: Model 273-241 | Catalog #: 273-241 $24.99
this fan is ultra quiet and will move 65 cubic feet a minute- about the size of your head 65 times a minute!

Fan Grill: Model: A2399 | Catalog #: 28-1119 $3.99
will keep your chin strap and fingers out of the blades

Screw-On Wire Connectors: Model: 64-3068 | Catalog #: 64-3068 $1.99
if you don't have butt connectors, or soldering ability

Extension Cord: Model: 61-2759 | Catalog #: 61-2759 $6.99
chop off the end or buy a switched lamp cord

For the 'Classic,' version:
Pre-cut twelve inch MDF, plywood, or melamine circle. $3.99

Four solid door stops. $2.49/pack of two

Four 2" long drywall screws.

Four small wood screws. Shorter than the thickness of the wood, yet with a large enough head to secure the fan grill in place.

One Cable Clip: Model: 278-1640 | Catalog #: 278-1640 $3.99
I know you'll use the other nine included on your computer desk rat nest


For the 'Modern' version:
6 or 8 inch Circular valve box $3.99

Four #8 or #10 machine screws 1" or longer






The Classic

The Modern


Last edited by ritchj on Thu, 14 Sep 2006 00:22:50 +0000; edited 1 time

'The Classic' version Steps:

1. Mark fan opening on one side of the wood and remove it.

2. Pre-drill holes for the doorstop 'legs.'

3. Screw the doorstop 'legs' in place.

4. Center the fan over the hole and secure it to the wood using the four drywall screws.

5. Wire the fan (chop off the female part of the extension cord) strip about 1/4 of an inch of the rubber jacket from the cord, use the wire nuts to wire the fan to the cord.

6. Secure the cord to the wooden base - this will make it harder to pull the wires out of the wire nuts.

'Modern' version:

1 Wire the fan (chop off the female part of the extension cord) strip about 1/4 of an inch of the rubber jacket from the cord, use the wire nuts to wire the fan to the cord.

2. Using a sharp knife notch the inside lip of the valve cover as shown in the Image A.

3. Using a twisting motion insert each bottom corner of the fan frame through the notch Image B.

4. Mark and carefully cut the material of the valve cover so that the corners of the fan drop into the top of the valve cover Image C.

5. Install the grill using the four machine screws Image D


Image A

Image B

Image C

Image D

Hey, that's hot! I mean, cool, I mean...

I was at first alarmed at the use of what appeared to be a DC fan wired directly to AC. I went and looked up the fan and, indeed, it's actually an AC fan. Sorry I doubted you.

Nice project.

The fan part number is sorta critical.

Plus that fan moves more air, is quieter, and cheaper than the DC version when you added the wall-wart power adapter.

8) The 'coolest' thing I have ever seen 8)

dude, you have way too much time on your hands.
nice work btw.

Who makes the helmet? It looks awsome.

Buy them books, send them to school....and they eat the books!


Nice invention !